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Engineering Manual
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GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Preface Contents
Grundfos supplies pumps for a range of mining applications, and this 5. What to mine and how..................................................................... 60
engineering manual provides an overview of the mining applications a. Copper.......................................................................................................................60
and processes in which Grundfos is involved. Mining can be roughly b. Gold............................................................................................................................60
divided into three types: metal mining, non-metal mining and coal c. Nickel..........................................................................................................................61
mining. The focus in this manual will be on metal mining, primarily on d. Zinc.............................................................................................................................61
extraction by leaching. There are of course many other ways to extract 6. Grundfos products............................................................................ 64
minerals than by leaching, but they will not be described in detail in NKG Industrial Norm pumps ISO 2858........................................................66
this first edition. HS Horizontal Split Case Pumps......................................................................66
Vertical Turbine Pumps...........................................................................................67
For non-metal and coal mining, the processes are not covered in SP Borehole Submersible Pumps....................................................................67
detail. However Grundfos pumps are still widely used for water intake, SP Borehole Submersible Pump Motors......................................................68
dewatering and dust suppression, all applications which are part of DWK Dewatering Submersible Pumps.........................................................68
the water management in most mining operations. DW Dewatering Submersible Pumps...........................................................69
Fire Pump Sets............................................................................................................69
As noted above, this is a first edition of the Grundfos mining CR- Multistage Vertical Centrifugal Pumps....................................................70
engineering manual and we will continue to update the content in CR High Pressure Vertical Multistage Pumps............................................70
upcoming editions, as we expand our offerings in the mining sector. CRH Horizontal Multistage Pumps................................................................71
Hydro MPC Muklti Pump Controlled Booster Pumps.............................71
Dosing Pumps.............................................................................................................72
Polydos Polymer / Lime Preparation Plant..................................................72
Contents SE/SL Drainage, Effluent pump...........................................................................73
AMD / AMG Mixers..................................................................................................73
Grundfos Electronic Control Systems LiqTec ................................................74
CUE..................................................................................................................................74
Introduction............................................................................................. 5
MP 204, CU 300, CU 301........................................................................................75
1. Grundfos and mining........................................................................... 7
7. Pump theory...................................................................................... 78
2. Mining methods................................................................................... 9
8. Pumps and motors............................................................................ 82
a. Open pit mining........................................................................................................9
9. General guidelines..........................................................................100
b. Underground mining........................................................................................... 10
SP pumps................................................................................................................... 100
c. Recovering from brines........................................................................................ 12
Lifetime of a pump in chloride......................................................................... 103
3. Applications in mining....................................................................... 16
Appendix 1 - Mine titles and definitions...................................................... 114
a. Main Mining Process............................................................................................ 16
Appendix 2 - Reference cases............................................................................ 118
b.Important factors as regards extraction processes.................................. 27
c. Raw water intake .................................................................................................. 27
d. Water treatment ................................................................................................... 30
e. Open pit drainage.................................................................................................. 36
f. Peripheral dewatering ......................................................................................... 40 ENGINEERING MANUAL
g. Underground dewatering and drainage...................................................... 41 Copyright 2012 GRUNDFOS A/S. All rights reserved.
h. Dust suppression................................................................................................... 44 Copyright law and international treaties protect this material. No part of this material may
i. Wastewater handling............................................................................................ 46 be reproduced in any form or by any means without prior written permission
from GRUNDFOS Holding A/S.
4. Wear & corrosion............................................................................... 50
All reasonable care has been taken to ensure the accuracy of the contents of this material:
a. Corrosion................................................................................................................... 52
However, GRUNDFOS shall not be held liable for any losses whether direct or indirect,
b. Erosion corrosion .................................................................................................. 54 incidental or consequential arising out of the use of or reliance upon on any content
c. Pump use and maintenance............................................................................. 57 of this material.
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GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Introduction
Pumps in mining
Pumps are used for multiple purposes in mining,
for example raw water supply, leach solutions
for extraction, dosing and adding chemicals,
dewatering, acid mine drainage, process water
pumping in the metal recovery plant and dust
suppression. In addition, utility pumps are
necessary for providing all amenities in the
workers town.
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In addition, Grundfos is a world leader supplying Service agreements recognize the greater
pumping solutions for water utilities, from raw requirements for maintenance for mining
water intake to water treatment, wastewater applications. A partnership with Grundfos focuses
transport and treatment, recycling and disposal. on not only the pumping solution but also the
Grundfos ensures that the town built for workers business aspects. As a partner, Grundfos offers
is fully equipped with utility pumps for all commissioning agreements to ensure correct
amenities. installation and service agreements with cover
for all eventualities, from routine maintenance to
With Grundfos as partner, a solution can often spare parts and pump audits.
be tailored to an application. Pumping solutions
offer great reliability with levels of continuous
operation that ensure a high level of stability
for operations. Tailored pumping solutions take
account of requirements for special constructions
to cope with aggressive media, and utilize sensors
and protection for pumps and motors that
warn of a potential problem, ensuring proactive
maintenance instead of reactive repairs or
breakdowns.
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2. Mining methods
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Blast mining An older practice of coal mining similar to long wall. The continuous miner shears
that uses explosives such as dynamite to break up coal panels 150 to 200 feet wide and more than a
the coal seam, after which the coal is gathered and half-mile long, depending on other things like the
loaded onto shuttle cars or conveyors for removal strata of the Earth and the transverse waves.
to a central loading area. This process consists of
a series of operations that begins with "cutting" Coal skimming While no longer in general use
the coal bed so it will break easily when blasted because of the massive amount of water needed
with explosives. This type of mining accounts for and environmental damage that followed, this
less than 5% of total underground production in method was developed in the late 1930s by
the US today. DuPont. It was much faster and less labour-
intensive than previous methods to separate the
Shortwall mining A coal mining method that lighter coal from the mining refuse (e.g. slate),
accounts for less than 1% of deep coal production, called "coal skimming" or the "sink and float
shortwall mining involves the use of a continuous method.
mining machine with moveable roof supports,
Underground mining, showing the need to dewater different areas continuously to avoid flooding
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Salar de Uyuni
Salar de Uyuni is the worlds largest salt flat
(dry lake), covering 10,582 km2. It is located
in the Potos and Oruro departments in
southwest Bolivia. Only trial brine production
is carried out.
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3. Applications in mining
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NKG Surface mounted pumping. Transfer of process leachate to storage prior Available in a range of SS materials to suit a For fluids that are aggressive and corrosive, confirm fluid
to processing. Leaching solution pumping into injection wells. In cast iron broad range of fluid chemistries. High flows chemistry, range of concentrations and temperatures.
material variants, general purpose pumping such as water transfer, fire and medium heads are achievable. Cast iron Correct mechanical seal selection is critical. Consider fluid
systems, dust suppression, hose down, truck wash and truck fill. and bronze materials available for more general SG in P2 hydraulic power calculation so that motor is sized
applications. Optimized hydraulics in housing correctly. Carefully consider NPSHa vs NPSHr including
and impeller for unimpeded liquid flow. Back ambient temp, altitude above sea level and vapour pres-
pull out design for easy dismantling and ser- sure of fluid.
vice. O-ring between pump housing and cover Single-stage standard pumps according to ISO 2858 and
means no risk of leakage. ISO 5199
Standard dimension according to ISO stand-
ards, robust design, wide range, standard
motor, adaptable to any application and
performance
SP Below ground bore mounted. Leachate pumping to surface. Available in a range of SS materials to suit a Stability of electrical supply both voltage and phase
broad range of fluid chemistries. Very deep balance is important particularly when gen sets are
bores and high heads achievable. One supplier employed. Fluids are aggressive and corrosive. Confirm
of the pump, motor and controls for an optimal fluid chemistry, range of concentrations & temperature.
system. Capable of operating in very deep Correct mechanical seal selection is critical. Consider
bores with high heads achievable. State of the fluid SG in P2 hydraulic power calculation so that motor is
art hydraulics provide high efficiency and low sized correctly. Consider use of anodes to provide cathodic
operating costs protection.
High efficiency, long service life as all compo- Sizes in 4", 6", 8", 12" submersible pumps.
nents are stainless steel, motor protection via
CUE or MP 204
CR Surface mounted pumping. Liquor processing applications where more Available in a much broader range of materi- For fluids that are aggressive and corrosive confirm fluid
exotic materials or very high pressures are required. Leaching solution als and configurations to suit a wider range chemistry, range of concentrations and temperature.
pumping into injection wells. General non potable mine water reticula- of fluid chemistries and temperatures. This Correct mechanical seal selection is critical. Consider fluid
tion and boosting via Hydro MPC systems, high pressure spray washing range is able to meet a wide range of flows and SG in P2 hydraulic power calculation so that motor is sized
and rinsing applications such as truck wash. Fire protection via hydrants heads with superior energy efficiency via lower correctly. Carefully consider NPSHa vs NPSHr including
and sprays. Mine camp accommodation facilities potable water supply. starting currents and accurate pump control of ambient temp, altitude above sea level and vapour pres-
e-Saver motors. Hydro MPC systems are capa- sure of fluid.
ble of meeting changing duty point require- Multistage centrifugal pumps.
ments whilst optimizing energy efficiency.
Reliability, high efficiency, service-friendly,
space-saving, suitable for slightly aggressive
liquids.
Dosing Chemical dosing of leachate chemicals Easy manual dose rate adjustment. Accurate Chemicals can attack certain materials. Always check
metering of chemicals to +/-1% of target pump head chemical compatibility. Size pump to achieve
flow. Chemical cost saving through preven- maximum dose flow rate in L/h.
tion of overdosing. Robust construction for
mining applications. Suitable for all weather
conditions.
Large user-friendly display, energy optimized
control, data communication, perfect constant
pressure, application-optimized software.
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GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
leach pad. Grundfos offers transfer pumps, dosing drive or various kinds of shaft seal solutions.
and chemical dosing pumps, and heap leaching,
Nickel
submersible and end-suction pumps covering the sulphide
entire process.
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GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
ii. Bio heap leaching with a diluted sulphuric acid, in this case
Bio heap leaching is used commercially and containing bacteria and nutrients. In addition,
covers certain natural bacterias ability to leach the heap is aerated to stimulate bacterial growth.
metals from sulphide minerals. The bioleaching The bacteria convert sparingly soluble metal
extraction method is used to extract for example compounds into water-soluble metal sulphates.
copper, gold and nickel, and involves several The fact that it is possible to leach sulphide
steps. First a large heap of crushed ore is built, minerals is what distinguishes bioleaching from
(for example copper or nickel sulphides). Then, conventional acid leaching where only oxidized
as with acid heap leaching, the heap is irrigated minerals are leached.
Discharges that do not meet the water quality criteria established in the permit must be treated.
Although heap leaching is a low-cost process, only some 60-90% can be recovered. Therefore it is
normally only used in connection with low-grade ores. Higher-grade ores are usually subject to more
complex milling processes. The actual process depends on the metallurgical properties of the ore.
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GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
NKG Surface mounted pumping. Transfer of process leachate to storage prior Available in a range of SS materials to suit a For fluids that are aggressive and corrosive, confirm fluid
to processing. Leaching solution pumping into sprays that broadcast over broad range of fluid chemistries. High flows chemistry, range of concentrations and temperatures.
the crushed ore stockpile. In cast iron material variants, general purpose and medium heads are achievable. Cast iron Correct mechanical seal selection is critical. Consider fluid
pumping such as water transfer, fire systems, dust suppression, hose and bronze materials available for more general SG in P2 hydraulic power calculation so that motor is sized
down, truck wash and truck fill. applications correctly. Carefully consider NPSHa vs NPSHr including
Standard dimension according to ISO stand- ambient temp, altitude above sea level and vapour pres-
ards, robust design, wide range, standard sure of fluid.
motor, adaptable to any application and perfor- Single-stage standard pumps according to ISO 2858 and
mance, EN 12756 shaft seal. ISO 5199
HS Surface mounted, high volume, high head, non-potable water pump- High energy efficiency, high reliability of bear- Carefully consider NPSHa vs NPSHr including ambient
ing applications such as storage dam to ring main for general mine ings and mechanical seals due to balanced axial temp, altitude above sea level and vapour pressure.
operations and radial loads. Long overall life and mean Horizontal split case pumps.
time between rebuilds.
Flange dimension according to EN 1092-2 (DIN
2501), robust design, double suction and volute
design, wide range, standard motor, adaptable
to any application and performance, removable
bearing housing for easy maintenance
SP Below ground mounted, peripheral bore field dewatering via intercepting Available in a range of SS materials to suit a Stability of electrical supply both voltage and phase
groundwater aquifers to lower water table below pit excavations. broad range of fluid chemistries. Very deep balance is important particularly when gen sets are
bores and high heads achievable. employed. Fluids are aggressive and corrosive. Confirm
fluid chemistry, range of concentrations and temperature.
High efficiency, Long service life as all compo- Correct mechanical seal selection is critical. Consider
nents are stainless steel, Motor protection via fluid SG in P2 hydraulic power calculation so that motor is
CUE or MP 204 sized correctly. Consider use of anodes to provide cathodic
protection.
4", 6", 8", 12" submersible pumps.
CR Surface mounted pumping. Liquor processing applications where more Available in a much broader range of materi- For fluids that are aggressive and corrosive confirm fluid
exotic materials or very high pressures are required. Leaching solution als and configurations to suit a wider range chemistry, range of concentrations and temperature.
pumping into injection wells. General non potable mine water reticula- of fluid chemistries and temperatures. This Correct mechanical seal selection is critical. Consider fluid
tion and boosting via Hydro MPC systems, high pressure spray washing range is able to meet a wide range of flows and SG in P2 hydraulic power calculation so that motor is sized
and rinsing applications such as truck wash. Fire protection via hydrants heads with superior energy efficiency via lower correctly. Carefully consider NPSHa vs NPSHr including
and sprays. Mine camp accommodatio starting currents and accurate pump control of ambient temp, altitude above sea level and vapour pres-
e-Saver motors. Hydro MPC systems are capa- sure of fluid.
ble of meeting changing duty point require-
ments whilst optimizing energy efficiency. Multistage centrifugal pumps.
Reliability, high efficiency, service-friendly,
space-saving, suitable for slightly aggressive
liquids.
Dosing Chemical dosing of leachate chemicals Easy manual dose rate adjustment. Accurate Chemicals can attack certain materials. Always check
metering of chemicals to +/-1% of target flow. pump head chemical compatibility. Size pump to achieve
Chemical cost saving through prevention of maximum dose flow rate in L/h.
overdosing. Robust construction for mining
applications. Suitable for all weather conditions.
Large user-friendly display, energy optimized
control, data communication, perfect constant
pressure, application-optimized software.
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GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
NKG Surface mounted pumping from shore or floating platform. Lower Available in a range of SS materials to suit a Water chemistry should still be considered here as source
volume water transfer applications from river or dam to water treatment broad range of fluid chemistries if necessary. water from dams can be corrosive due to constant recy-
operations if necessary due to quality requirements at final destination. High flows and medium heads are achievable. cling and reuse. For fluids that are possibly aggressive and
Tank to tank raw water transfer applications as required in some batch- Cast iron and bronze materials available for corrosive, confirm fluid chemistry, range of concentrations
ing operations. more general applications. and temperatures. Correct mechanical seal selection is
Standard dimension according to ISO stand- important. Carefully consider NPSHa vs NPSHr includ-
ards, robust design, wide range, standard ing ambient temp, altitude above sea level when making
motor, adaptable to any application and perfor- pump selections.
mance, EN 12756 shaft seal. Single-stage standard pumps according to ISO 2858 and
ISO 5199
HS Surface mounted pumping from shore or floating platform. High Volume High energy efficiency, high reliability of Consider the mines future raw water volumetric require-
water transfer applications from river or dam to water treatment opera- bearings and mechanical seals due to more ments. If shore based pumps, ensure that water level will
tions if necessary due to quality requirements at final destination. balanced axial and radial loads. Long overall life not drop beyond NPSHa vs NPSHr limit; also consider dam
and mean time between rebuilds. spillway height to ensure pumps are above flood level if
Flange dimension according to EN 1092-2 (DIN water level rises. Water chemistry should still be consid-
2501), robust design, double suction and volute ered here as source water from dams can be corrosive due
design, wide range, standard motor, adaptable to constant recycling and reuse. For fluids that are possibly
to any application and performance, removable aggressive and corrosive, confirm fluid chemistry, range of
bearing housing for easy maintenance concentrations and temperatures. Correct mechanical seal
selection is important. Carefully consider NPSHa vs NPSHr
including ambient temp, altitude above sea level when
making pump selections.
Horizontal split case pumps.
SP Submersible pumping from floating platform in dam or river direct to Available in a range of SS materials to suit a When installed in river, ensure pump protected adequately
mining operations or to water treatment operations if necessary due to broad range of fluid chemistries. Very deep from currents and debris. Consider using heavy concrete
quality requirements at final destination. bores and high heads achievable. casing. When installed in dam also consider protection
from foreign debris. Self-cleaning screens are good for this
High efficiency, long service life as all compo- purpose.
nents are stainless steel, motor protection via
CUE or MP 204 4", 6", 8", 12" submersible pumps.
DWK Durability, ductile/high-chrome impeller, easy Heavy-duty dewatering pumps. Need small installation
to operate, high efficiency, compact design, space.
high-pressure capacities, flame-proof applica-
tions, size of DWK is able to fit to limited space.
SE/SL Service friendly, relaible and energy efficient, Heavy duty drainage pumps
AUTOadapt, S-tube or SuperVortex impellers.
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GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
d. Water treatment
Water treatment describes those processes
used to make water more acceptable for a
desired end-use, and for mining operations
and mineral processing, Grundfos can supply a
complete water treatment solution tailored to
the application, from simple filtration for process
water to the stringent quality standards for water
supply to the mining town.
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SES On-site generation of sodium hypochlorite using clean water, salt and On-site generation means you only make up Commercial grade (12%) Sodium Hypochlorite degrades
electricity, for disinfecting drinking water. what you need. No loss of chemical supply due continuously once manufactured. This increases in ambi-
to transport strikes, accidents or road closures. ent temperatures above 20C and where dust contamina-
Low solution strength of 0.7% free chlorine tion is a significant hazard. The degrading chemical gasses
means liquid is not a toxic substance and is off CO2 gas, which forms bubbles in the dosing pump head
classed as food greade saline solution. No as air-locks the pump. On-site low grade generated solu-
degassing and low degrading of chemical. Only tions eliminate this problem.
stored ingredients is salt, which can be stored
on-site for years. Can operate on off-peak power
saving energy power costs. Simple to operate,
low maintenance and operation requirements.
DIA-2Q Chlorine and pH on-line analyser to measure and control the dosing rate Accurate dosing of disinfection and pH chemi- Chemical dosing must be monitored at all times
of water treatment chemicals. cals. Control dosing rate by both water flow and
set-point control. Full compound-loop PID con-
troller. Can control a water treatment chemical
dosing system without additional SCADA/PLC
control system. Prevention of over/under dosing
which could be detrimental to the health of the
mine workers.
DIT-L Chemical photometer testing unit. Hand held photometer test the level Only way to test and check the accuracy of DIT-L photometer uses reagent tablets, which do not
of free chlorine and the pH of the water. Must be used to calibrate the the chlorine/pH reading given by the DIA-2Q. degrade compared to liquid reagents which degrade
on-line analyser. Accuracy ensures cost savings and miners' rapidly.
health with treated drinking water.
Dosing stations Dosing stations combine the chemical dosing pump/s with all the acces- Pre-designed and part number configured Select the correct size and material mix for the dosing
sories and plumbing required to operate a complete system. standard dosing stations can be ordered station. Check that the dosing footprint will fit in the site
directly from the price book. No design require- location.
ment, No onsite installation. Dosing stations
arrive on-site fully assembled and tested ready
for installation and commissioning. No on-site
delays getting the water treatment system in
operation. Every system has a full parts listing,
3D as-built drawings and operation manual.
Containerised systems Any application where chemical dosing is required to be set up quickly All Chemical dosing systems can be pre-built These systems are made to order. Full consultation of
and efficiently as a self-contained and housed, drop-in unit. into a 10, 20 or 40' insulated shipping container access, entry and exit points, wiring connection standards,
and delivered to site to be set down onto liquid connection standards and positioning of all internal
cyclone-proof mountings ready to be connected components can be made to the customers specifications.
to the process system.
SE/SL Submersible pumping from within wet well without cooling jacket and Available with S-tube high efficiency impeller Consider wet well or dry well application. Consider use
dry well with cooling jacket where suspended soft solids are present prior technology and enhanced high efficiency motor of Grundfos dedicated controls to enhance and optimize
to primary filtration. technology. SmartTrim impeller adjustment operational performance.
to maintain impeller clearance and efficiency.
Non-clogging impeller design means no jam- Heavy duty drainage pumps.
ming, blocking or ragging.
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GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
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f. Peripheral dewatering offering a fast and effective solution when g. Underground dewatering and drainage
A series of peripheral deep wells are typically greater depth and power is required. A flexible Underground dewatering and drainage is
installed around open pit mines to reduce the riser hose makes sure that such additions are necessary to ensure that mining operations
risk of flooding, which makes them unsafe. handled easily and problem-free. With possible continue unhindered. Dewatering from rock
Although the complete removal of water is nearly great fluctuations in demand for performance faces in mine shafts, quarries, or gravel pits often
impossible due to natural processes, Grundfos SP and multiple pumps installed, adding variable contains abrasives such as sand, clay particles,
groundwater pumps reduce the amount of water frequency drives will equalize the hydraulic load drill cuttings, and other potentially damaging
entering mines significantly. The SP pump resists to the wells, automatically adjusting pump speed objects, and the pH value is usually very low.
sand and other abrasive materials and the extra to demand. This ensures optimal dewatering Grundfos dewatering pumps are designed to work
high grade stainless steel version is suitable for around the mine periphery. in the toughest environments and can be found
very severe conditions. Fitted with a frequency in mining applications and offshore industries
converter, Grundfos pumps will automatically Grundfos motor protection is developed for worldwide.
adjust their speed to the demand. pumps and not just the motor, and used together
with an Interface Module ensures dedicated Solid construction with high-grade materials such
Peripheral dewatering and the maintenance of a dewatering level control that offers greater as chromium steel and silicon carbide means
constant water level typically involve a number of protection, because parameters other than the Grundfos AP range of dewatering pumps is
wells installed around open-pit mines. Grundfos electrical conditions in the motor are measured. ideal for pits, for temporary or fixed installation,
offers a flexible and effective solution for This makes possible timed stop/start routines and offers high-pressure pump performance
removing clean or dirty water with particles and that dont damage the pump or motor and helps unhindered by sand or other abrasives. Solid cast
adjusting water levels with bore holes from 30 m avoid sudden outages and the risk of flooding. iron construction and narrow design characterises
to 600 m. Higher-grade material anti-corrosion See more under Grundfos products (Chapter 6). the Grundfos DWK range of dewatering pumps,
versions are also available for severe conditions and this range can pump small stones at greater
with low pH and chlorides. flow than the Grundfos AP range.
For example, Grundfos supplies SP pumps with The Grundfos SE1/SEV series of pumps are
an empty chamber suitable for mining needs, specifically designed for durable use and heavy
flows and can be installed dry or submerged.
Higher-grade material anti-corrosion versions
are also available for severe conditions. See more
under Grundfos products (Chapter 6).
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The Grundfos range of powerful wastewater dead zones. These products offer robust design
pumps is designed for handling drainage, with corrosion resistant materials, easy service
effluent and sewage from mining operations and and maintenance, and trouble-free operation in
mineral processing, as well as from the mining difficult environments.
town. With highly efficient, non-clogging S-tube
or SuperVortex impellers, Grundfos SE pumps A complete range of dosing pumps systems for
ranges in corrosion resistant materials ensure large or small volumes and based on different
free passage of large solids, reducing greatly the technologies is available, and Grundfos also
risk of clogging. supplies electronic and electrochemical
accessories for complete control as well as
Grundfos mixers and flow makers offer an PLC-controlled, fully automatic systems for dry
optimum, energy efficient solution for mixing material preparation and reliable dosing. See
in tanks of any size, creating a bulk-flow with an more under Grundfos products (Chapter 6).
almost uniform flow velocity and limited risk of
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Definitions of wear
Aggressive mine water and chemicals used in mining may lead to wear. Wear can in general be
divided into erosion, abrasion and incrustation problems on pipes, well screens, ponds, bridges,
water intakes and pumps.
Erosion
erosion corrosion is when the liquid velocity, air or particles in the liquid erodes and removes the
protective film of the metal and exposes the reactive metal to high flow velocity, thus accelerating the
corrosion process. It is also erosion if the particles impact so hard on the surface that you have wear.
Abrasion
abrasive wear occurs when hard particles are forced against and move relative to a solid surface.
The illustration below shows the three major types of abrasion Gouging, High Stress Grinding and
Low Stress Grinding. This is essentially what happens between the seal faces in a shaft seal when
there are small particles in the liquid.
Incrustation
this results from the deposit of minerals in and outside the pumps. Acidic mine water typically
contains elevated concentrations of sulphate (SO4), iron (Fe), manganese (Mn), aluminium (Al) and
other ions. Under certain circumstances (such as pressure, pH- and temperature changes) these
metals can precipitate from the solution. Incrustation can also result when pumping lithium brines
and other salt compounds.
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GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Grundfos recommends this type of stainless chloride. Presence of chloride in leach solutions
steel when it is not clear whether the acidic increases the corrosiveness of water. Selecting
water is sufficiently oxidized or when the water the right pump materials is thus very important.
composition varies a lot. However, if the chloride Put another way, material selection is the most
content is very high, Grundfos recommends the important method of corrosion prevention.
use of stainless steel EN 1.4539 (AISI 904L) rather Choosing the right materials based on the water
than EN 1.4401 (AISI 316). As regards cast iron an composition (pH value, chloride, oxidizing species
increase in the corrosion rate must be expected and temperature) reduces the risk of corrosion and
in liquids with pH value lower then 6.5. Titanium, prolongs the equipment lifetime.
on the other hand, is superior to stainless steel
when the chloride content is so high that it causes
corrosion problems with stainless steel EN 1.4401 b. Erosion corrosion
(AISI 316) and EN 1.4539 (Aisi 904 L). The pH value Erosion corrosion is another critical issue.
of dewatering solutions from pit and waste Particulates are often carried in a corrosive
rocks is normally higher (pH of 3-7) than that of a medium through pipes, tanks and pumps. The
leach solution and the corrosiveness is therefore presence of these particulates erodes and removes
generally lower. the protective film of the metal and exposes
the reactive metal to high flow velocity, thus
Corrosion caused by chloride accelerating the corrosion process.
Depending on the geology of the mine sites
the ore or groundwater contains more or less
Examples of corrosion
The degree of erosive wear depends on: These many influences dictate the amount of
erosion, and there are broadly speaking only
Speed of the particles (velocity of liquid) three ways to avoid erosion:
Amount of particles
Shape of particles A pump in a harder metal
Hardness of the particles Lower flow in pipes and pump by using a slow
The pump material running pump with a 4 or even 6 pole motor
Impact direction Filter the particles away (normally not possible
because the idea is to transport them
somewhere with the liquid)
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GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
However, whatever is done to avoid wear/erosion, NBG/NKG stainless steel end-suction pumps
it may not be possible to avoid it completely. Wear Pump size (NB, NK) Pump size (NBG, NKG) Impeller passage (mm)
Impeller passage (mm)
can at least be limited to an acceptable level by
50 8 50 8
selecting the correct pump type.
50 7 50 7
50 4 50 4
Standard pumps supplied by Grundfos and this
50 8 50 8
is true for other manufacturers as well are not 50 7 50 7
built for pumping liquids containing particles. We 50 7 50 7
state that the CR and NBG/NKG pump ranges are 50 4 50 4
not suitable for pumping solids of any kind, but 65 8 65 8
Grundfos is aware that some customers need to 65 8 65 8
know what size and content of solids the pump 65 7 65 7
can handle. Although an exact value cannot be 65 6 65 6
given because this depends on the type of solids 65 5 65 5
and fibres, the tables below show the free passage 65 12 80 12
through the impeller of individual pump types, 65 10 80 10
showing the maximum solid size for trouble-free 65 10 80 10
operation. If pumping solids, the pump must be 65 7 80 7
maintained more often. 65 7 80 7
80 12 100 12
Impeller free passage 80 11 100 11
The values indicate the maximum size of solid 80 13 100 13
particles that can pass through the pump. 80 11 100 11
80 13 100 13
100 12 125 12
100 12 125 12
CR multistage centrifugal pumps
100 15 125 15
Pump type Impeller passage (mm) 100 18 125 18
CR 1s 2.38 100 11 125 11
CR 1 2.5 125 17 125 17
CR 2 2.7 125 20 125 20
CR 3 3.1 125 19 125 19
CR 4 2.9 125 17 125 17
CR 5 5.5 125 12 125 12
CR 8 4.4 150 17 150 17
CR 10 4.5 150 20 150 20
150 24 150 24
CR 15 6.5
150 14 150 14
CR 16 6.5
150 15 150 15
CR 20 6.8 200 23 200 23
CR 32 8.0 200 22 200 22
CR 45 9.5 200 31 200 31
CR 64 13.0 200 29 200 29
CR 90 16.0 200 18 200 18
CR 120 16.0
CR 150 24.0 c. Pump use and maintenance
In general, it is important to inspect and maintain pumps in mining applications on a regular basis.
Maintenance of the pump implies replacing the rotating parts such as impellers, shaft and shaft seal.
A combination of factors, such as corrosion, wear and incrustations, may also cause damage to the
pump, as mentioned above.
56 57
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
58 59
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
c. Nickel
5. What to mine and how Nickel occurs in nature principally as oxides,
sulphides and silicates. Ores of nickel are mined
a. Copper The metallic copper that is left at the bottom of in over 23 countries and are smelted or refined
Copper ore is mined underground and from the converter is known as blister copper. It is very in 25 countries, most importantly Russia, Canada,
surface mines, with most of the copper ores pure, but further refining is necessary to remove New Caledonia, Australia, Indonesia, Cuba, China,
mined today being oxide or sulphide ores. From impurities consisting of small amounts of gold, South Africa, Dominican Republic, Botswana,
the mines, copper ore is taken to mills, where it silver and other precious metals. Columbia, Greece and Brazil. Important nickel
is crushed and finely ground in preparation for refineries also operate in Norway, Finland, France,
refining. The method of refining varies with the This refining is done electrochemically, using a Japan and the United Kingdom. Primary nickel is
type of ore. process similar to the one used with oxide ores. produced and used in the form of ferronickel,
In this case, however, the anode is moulded nickel oxides and other chemicals, and as more
For copper oxide ores, the copper is usually from blister copper and decomposes during or less pure nickel metal. Nickel is also readily
dissolved with heap leaching as described above. electrolysis. The direct electric current that flows recycled from many of its applications, and large
The copper can be recovered from the leaching between the electrodes placed in an electrolytic tonnages of secondary or "scrap" nickel are used
solution through electrolysis (electro winning). tank transfers the copper of the blister copper to supplement newly mined metal.
In this process, a direct electric current is set anode onto the cathode. The precious metal
up between positive and negative electrodes impurities collect at the bottom of the tank. Only about 1.4 million tons of new or primary
placed in the solution. The negative electrodes nickel are produced and used annually in the
cathodes are usually made of thin sheets of world, compared with over 10 million tons of
pure copper and the positive electrodes anodes b. Gold copper and nearly 800 million tons of steel.
are usually made of lead. The electric current How gold is mined depends on the deposits. Nickel is often extracted with acid heap leaching
causes the copper in the solution to be deposited Lode deposits are concentrations of gold found or froth flotation.
on the cathodes as a coating of pure copper. in solid rock. If the gold-bearing rock is located on
the earth's surface, the mining company will use
Copper sulphide rich ores are first treated by a open-pit techniques. First, miners drill a pattern d. Zinc
process called froth flotation. In this process, air of holes, which they then fill with explosives. Zinc is a bluish-white, lustrous, metallic element.
bubbles are produced in a mixture of ground Next, they detonate the explosives to break up Zinc is one of the most widely used of all metals
copper ore, water and chemical reagents. The the ground so it can be loaded into haul trucks. in industry. Zinc occurs in nature in a variety of
particles of copper-bearing minerals in the ore ores, the most common being sphalerite (zinc
stick to the bubbles and float to the top of the If the lode deposit is located beneath the earths sulphide). Canada leads the world in the mining
mixture, where they can be skimmed off. surface, underground mining is necessary. In of zinc, followed by Australia, Peru, and China.
this case, miners drill a shaft, or an adit, into The leading smelters of zinc are Canada, Japan,
The copper-bearing minerals are roasted to drive the ground to access the lode. Then long vertical and China.
off a part of the sulphur. The resulting product is tunnels are dug, known as stops, which extend
smelted, yielding a molten combination of copper from the top of the ore block to the bottom. After As part of the extraction process, zinc ores are
sulphate and iron sulphide called matte. Some drilling and loading explosives into the ore block, usually roasted to convert the zinc in the ore into
light impurities in the matte combine to form the miners detonate the explosives, causing zinc oxide. Most zinc produced today is obtained
slag, which is removed. The matte is then poured broken ore to fall to the bottom of the stops. from the oxide by an electrolytic process. In
into a converter, where air is forced through it to The ore is loaded into trucks and taken to the this process, the zinc oxide is dissolved in an
burn out the remaining sulphur and to oxidize surface. Cyanide leaching has been the dominant acid and the resulting solution pumped into an
the iron. At this stage, most of the remaining gold extraction technology since the 1970s. This electrolytic cell. An electric current is applied
impurities, including the oxidized iron, float to process is not described in this manual between the electrodes in the cell, causing
the top of the matte to form more slag, which is the zinc in the solution to be deposited on the
poured off. negative electrode (electrowinning).
60 61
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
6. Grundfos products
62 63
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
6. Grundfos products
Product matrix
Product Application
Pump size Peripheral Open pit Underground Heap Wastewater Settlement Dust Processing Spillage In-situ Raw water Water Lithium
(NB, NK) dewatering dewatering dewatering / leaching handling pond suppression control leaching intake treatment
drainage
NKG X X X X X X
HS X X X X
Vertical tur-
X X X X
bine pumps
SP X X X X X X X X X
SP motors X X X X X X X
DWK X X X X X X
DW X X X
DWM X X X
Fire pumps X
CR X X X X X
CR high
X X
Pressure
CRH X X X
Hydro MPC X X
Dosing X X X X X X
Polydos X X X X X
SE/SL X X X X X X X
AMD/AMG X
Controls X X X X X X x x x x x
64 65
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
66 67
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
68 69
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
CR High Pressure Vertical Multistage Pumps Hydro MPC Muklti Pump Controlled Booster Pumps
70 71
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
72 73
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
APPLICATIONS:
Monitoring and protection of pumps and processes. APPLICATIONS:
Monitoring and protection of pump
Features and benefits installations.
Protection against dry running
Protection against liquid temperatures exceeding Features and benefits
130 C 5 C Protection against dry running and too high motor
Protection against too high motor temperatures temperature
Manual or automatic restarting possible from a Constant monitoring of pump energy consumption.
remote PC
Simple installation (plug-and-play technology) Options
Robust sensor. Connection to large control systems via bus
communication
Connection of sensors enabling control based on
sensor signals.
Control and monitoring units Wireless remote control via Grundfos R100, MI 201,
Control and monitoring units MI 202 and MI 301.
CUE
Technical data
Mains voltage:
1 x 200-240 V
2 x 200-240 V
3 x 380-500 V
3 x 525-600 V
3 x 575-690 V.
Applications
Adjustment of the pump performance to
the demand. Together with sensors, the
CUE offers these control modes:
proportional differential pressure
constant differential pressure
constant pressure
Frequency converters for three-phase constant pressure with stop function
Pumps constant level
constant level with stop function
constant flow rate
constant temperature.
The CUE can also be controlled by an
external signal or via GENIbus.
74 75
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
7. Pump theory
76 77
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
SP A, SP
9
generally of interest:
33.53 8.035 2.588 0.677 0.346
2.138 1.174 0.730 0.415 0.312
1.5 25 0.42
49.93 11.91 3.834 1.004 0.510
2.565 1.409 0.876 0.498 0.374 0.231
1.8 30 0.50
69.34 16.50 5.277 1.379 0.700 0.223
2.993 1.644 1.022 0.581 0.436 0.269
2.1 35 0.58
91.54 21.75 6.949 1.811 0.914 0.291
Flow Designation Q Unit m3/h Cubic meter per hour 2.4 40 0.67
1.879
27.66
1.168
8.820
0.664
2.290
0.499
1.160
0.308
0.368
2.349 1.460 0.830 0.623 0.385 0.229
3.0 50 0.83
and operation of pumps, there are a further two 10.5 175 2.92
2.904
33.32
2.182
16.66
1.347
5.179
0.803
1.488
0.576
0.670
0.434
0.338
0.337
0.184
The table is calculated in accordance with H. Lang's new formula a = 0.02 and for a water temperature of 10 C.
Transportation of any kind of fluid in a piping The head loss in bends, slide valves, T-pieces and non-return valves is equivalent to the metres of straight pipes stated in the last two lines of the table.
To find the head loss in foot valves, multiply the loss in T-pieces by two.
system creates friction, and thereby losses. That Friction loss Friction loss depends on the viscosity of the fluid.
means loss of energy and loss of pressure. It is Friction losses occur in the water pipe, in the For our purposes, the only friction loss referred to
the velocity of the fluid that creates the pressure elbows, in Ts, in valves, and so on. The friction loss is for water. 97
loss. The higher the velocity, the higher the loss. is dependent on the flow and is a constant for the
device. Vapor pressure
The fluid velocity (v) in a given pipe can be Water boils at 100C, although this is only true as
calculated from the flow. Pipes are a special situation. Here the friction loss is long as the atmospheric pressure is normal. When
also dependent on the length and the surface of the the pressure drops below the atmospheric pressure,
v= Q A xc
pipe. All pipe manufacturers have their own pipe water will boil at much lower temperatures. As an
loss tables that they make available and friction example, if the pressure drops to 0.1 bar, water will
In order to minimize the pressure loss it is usually loss data can be obtained from the manufacturer start boiling already at 45C. The atmos-pheric
recommended to keep the velocity in a pipe of the equipment. An example is shown above pressure is also lower at higher elevation. This
below 2-4 m/s, depending on the situation. for water in plastic pipes. It is the sum of the phenomenon becomes an important issue when
friction losses from all components in a piping working with pumps.
system that determines the total friction loss.
78 79
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
80 81
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Centrifugal pump main components Radial flow, mixed flow and axial flow pumps Surface/dry installed pumps and submersible
8. Pumps and motors pumps
Impeller types for different pressure and flow:
Usually a pump is installed in a dry environment.
Centrifugal pump types For outdoor use the motors must have an enclosure
The centrifugal pump has a stationary part and d2 class intended for an outdoor environment. These
a rotating part. The rotating part is called the are typically end suction pumps, split case pumps,
impeller. The impeller has a number of vanes and so on.
which force the water to rotate and creates flow.
d1
Radial flow Submersible pumps are pumps with the pump
The stationary part is called the pump housing, or Shaft seal
d2/d 1 = 3.5 - 2.0 impeller body submerged in the fluid it is supposed to pump
pump bowl. The bowl also has a number of vanes and there are two basic types, both for deep well
called guide vanes. Their function is to stop the Outlet applications:
waters rotation and to convert the d2
energy in the rotation to pressure. Inlet
Vertical turbine (VT) pumps have the pump body
submersed in the fluid, but the motor is installed
Single stage pumps versus multistage pumps above ground and connected to the pump body
d1
Mixed flow with a long shaft, the line shaft.
Single stage pumps have only one impeller and impeller
d2/d 1 = 2.0 - 1.5
one pump housing. The pressure is limited to what Submersible pumps, also called deep-well
that specific pump impeller type can produce. submersible pumps, have typically the same pump
d2
body as the VT pumps, but the motor is a special
Multistage pumps have several impellers and Outlet
design and installed beneath the pump. The
pump housings or bowls. If a single-stage pump Inlet
submersible motor has been designed to operate in
can generate 3 bar, then a two stage pump with d1 water under high pressure.
the same type of impeller and bowl can generate Mixed flow
6 bar, a three stage pump with the same type of d2/d 1 = 1.5 - 1.3 impeller
Cavitation
impeller and bowl will generate 9 bar and so on. Cavitation is a phenomenon caused by the water
d2 boiling. As described earlier, the
Deep-well submersible pumps are most often Impeller
water will boil at temperatures
multi-stage pump types. Besides generating a lower than 100 C, if the pressure
static pressure for the application, they have to Pump housing
drops below 1 atm. Cavitation
generate an additional pressure in order to lift d1 can be heard as a loud noise and
the water from deep underground. This requires Mixed flow
Bearing
vibration, and it is devastating for
typically a multi-stage pump. d2/d 1 = 1.2 - 1.1 impeller the pump.
Electric motor Impeller
d2 However, it is not the water boiling
Axial flow that does the damage. It is when
impeller the water is changing its state from
vapor to water that the damage
occurs. The vapor bubbles in the
Neck
water implode causing noise, and
rings
followed by a heavy mechanical
d1 impact, which will destroy the
d1 = d2 pump if cavitation takes place over
Pump
housing an extended period.
Shaft seal
82 83
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Head 50
design of the pump.
A pump delivers flow and head, or pressure. The 40
125
relation between flow and head is shown in the As described earlier, the situation where the
100
P2
Power curves lower the inlet and reduce the suction lift
NPSH
12 [kW]
Power consumption
The power curve below shows the hp or kW reduce friction loss in the suction pipe
10 100
required shaft power or motor size. On the curve lift the suction water level
4
NPSH
40
2 20
below the maximum kW is 105, which is the shaft 0 0
0 25 50 75 100 125 150 175 m3/h
power the motor must deliver. Minimum motor
p2
size is in this case therefore 110 kW.
Q1 Q2 m3/h
The system curve by definition starts at zero
kW
The duty point of the pump is typically a fixed and goes through the pumps duty point on the
Pressure [Pa]
a b
flow and head. From the pump curve the
110 pump curve. It is used to better understand what
100
corresponding flow and head can be read. A 80
will happen when we are trying to regulate the
certain flow Q1 will give a corresponding pressure 60 performance of the pump.
p1
H1, and the flow Q2, will give the pressure H2. 40
p
The pump can operate from zero flow (and max
20
Vapour pressure The definition mentioned above is different when
0
head) to max flow (and zero head). However, both 0 25 50 75 100 125 150 200 m3/h the pump has a static lift, as shown below.
extremes must be avoided for several reasons.
Impeller inlet Impeller outlet
Net Positive Suction Head, NPSH
Pump Efficiency Net Positive Suction Head (NPSH) is used as a
Pump efficiency is a term for how effective the Pumps at work, system curve
suction pressure safety limit, in order to avoid A pump is always part of a bigger system, such
pump is converting the absorbed energy to cavitation. When the water enters the impeller of
hydraulic energy. The higher efficiency a pump as a water supply system. That means there is a
a pump there is often already a vacuum, P1. pipe most often entering the pump (inlet pipe
has, the lower its energy consumption.
or suction pipe), and there is always a pipe going Q
Q1
A typical efficiency curve is shown below. The m out of the pump (outlet pipe or discharge pipe).
curve has a maximum point, which is typically
NPSH Friction loss occurs in the pipes, and in the piping In those situations the zero point starts on the
12
the pumps duty point. In the example below the 10
system there are often elbows, tees, valves, filters, y-axis at the head h, which is the static lift of the
duty point is at 165 m3/h. As soon as the flow is 8 and so on, all of which adds friction to the water water. These situations always apply when deep-
changed to either more or less, the efficiency of
6
flow. The friction loss increases with the flow in well submersible pumps or turbine pumps are
4
the pump goes down, and it drops to zero at both 2
the 2nd power. used. Q Q
1
ends. 0
0 25 50 75 100 125 150 200 225 m3/h
Each pumping system has a unique system curve,
Operation outside bold line limits (75 m3/h and which is constant, as long as the friction is not
215 m3/h) is not recommended. changed, for instance by using a valve, which
84 85
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Hs
86 87
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Comparison of performance regulation Power considerations and efficiencies energy that comes out of the pump as a product
The chart below shows the main differences between the various approaches to pump performance Electric motors convert electrical energy into of head and flow.
regulation. mechanical energy, which is used to drive the
pump. Motor protection
Method Continuous The resulting performance Overall efficiency Relative power In order to avoid unexpected breakdowns, costly
adjustment curve will have of the pump consumption by 20% P1 is the energy consumed by the motor. This can repairs and subsequent losses due to motor
possible? system reduction in flow
be read on the meter, and is the amount of energy downtime, it is important that the motor is fitted
Throttle control Yes Reduced Q Considerably 94% the power company is charging for. with some sort of protective device.
reduced
H [m]
H [m]
H [m]
H [m]
76
76
76
70
70
70
Throttle valve P2 is the motor shaft power, and this number For external protection against short circuits
Throttle valve
is always lower than P1, because there is a in the whole installation, external protection
55
55
55
certain electrical loss in the windings, and some devices are normally different types of fuses or
Q
Q
P Q
P222
P Q
P
100%
100%2
mechanical friction losses. P2 is also referred to as short circuit relays. This kind of protection device
100%
94%
94%
94%
Hn Hx Valve
50
50
50
60
60
60
l/h
Q [m
Q [m 33/h]
/h]
Q [m 3/h]
motor size. How big is your motor? means: how is compulsory and legal and placed under safety
Bypass control Yes H [m]
H
H
[m]
[m]
Reduced H and changed curve Considerably 110% much is your P2 of the motor? regulations.
H [m]
reduced
Bypass valve
Bypass valve The ratio between P2 and P1 is the motor efficiency, External protection against overload of specific
70
70
70
55
55
55
P2
P 110%
Q
Q
Q
where both P1 and P2 are in W or kW or hp. equipment is important to avoid the overload of
P
50 60 81 Q [m 33/h]
l/h
If the motor
Hn
sizeValve
Hx
is listed in hp, the formula for breakdown of the motor. This type of protection
Q [m /h]
Modifying impeller No H
H [m]
H [m]
[m]
H [m]
Reduced Q and H Slightly reduced 67%
diameter
70
70
70
P3 is the shaft power input required to drive the
pump and is usually the same as P2. But in cases
55
55
55
D P
P222
P
P2
100%
Q
Q
Q
Q
D where pumps have a long shaft such as a vertical
turbine pump, the friction in the long shaft
100%
100%
67%
67%
67%
50
50
50
60
60
60
Q [m
Q [m 3/h]
/h]
Q [m 33/h] bearing can be significant, and P3 is therefore
l/h
Hn H
lower than P 2. x
Speed control Yes H
H [m]
H [m]
[m]
H [m] Reduced Q and H Slightly reduced 65%
70
70
Speed controller Phyd, or P4, is the hydraulic power. This is the
Speed controller 70
55
55
55
Q
Q
Q
Q Q
Q
P2
P Q
P2
2 Q
P
100%2
100%
P1
100%
65%
65%
65%
50
50
50
60
60
60
Q [m
Q
l/h
[m 33/h]
/h]
Q [m 3/h]
Hn Hx Hy
Electric motors
An electric motor converts electrical power to mechanical
power.
P2
Motor components P3
An electric motor has a stationary part, the stator, and a
rotating part, the rotor. The stator is built of laminated steel
plates with slots on the inner diameter, in which are inserted
Built-in motor protection with thermal overload-
copper wire. The rotor is also built of laminated steel plates
protection avoids damage and breakdown of
with slots or holes on the outer diameter in which are inserted
motor. The built-in protector always requires an
copper or aluminum bars. Phyd
external circuit breaker, while some built-in motor
protection types even require an overload relay.
An electric field induced in the stator forces the rotor to rotate.
88 89
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Monitoring
breakdown), causes can be:
Locked rotor Phase sequence
Phase breakage Harmonic distortion
Fuses and circuit breakers Power factor
Fuses:
1-ph start and run capacitors
Fuses prevent short circuits from damaging the Operating hours, since reset and accumulated
installation and in worst case causing a fire.
It is essential that the fuse trips out before Number of starts, since reset and accumulated
thermal damage of other parts of the
Energy consumption, kWh, since reset and accumulated
installation occur because of short circuits.
Overload relays:
Make it possible for the motor to handle harmless The monitored data can be transmitted to a Heat
temporary overloads without interrupting the central controller, which can then control the Underload/dry run
circuit, i.e. motor starting. pump. This device can be used on any AC electric
motor up to 999A, or approximately 700 hp Over voltage
Protection
Trip and open a motor circuit, if the current depending on the voltage.
Under voltage
exceeds its limits and might damage the motor.
Are reset either automatically or manually once Phase unbalance/loss
the overload situation has passed.
Overload
Faulty capacitors
90 91
-2-A
GRUNDFOS
60
-2-AA
MINING MANUAL GRUNDFOS MINING MANUAL
400 40 -1
-1-A
Pump sizing The customer informs that the duty point required To calculate how much head the pump must Installation pit
20 pump supplier will normally select a pump
The will be around 210 m3/h. The Grundfos submersible produce, consideration must be given to the four
with the highest efficiency for the operating pump type SP215 can give 210 m3/h, which is close elements of pressure a pump has to overcome:
conditions. To find out if the operating conditions to the maximum efficiency, and this pump is
0 are0 stable, the process for calculating the relevant therefore selected (see the curve below). Pressure needed for the application devices
data 0could be as40
follows: 80 120 160 200 240 280 Q [m/h] (sprinklers, spray heads, drippers, and so on) Static
Friction loss in the piping system, pipes, water
screens, valves, elbows, tees, and so on level
0 20 40 60 80 Q [l/s]
p H Eta Elevation lift Dynamic
[kPa] [m] [%] Suction lift Drawdown water
160 16 Eta 80 Cone of level
For a deep-well pump, such as a submersible or depression
120 12 60
a vertical turbine, another consideration is the
80 8 40
drawdown of the static water level. The static
Suction lift
Screen losses
92 93
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Lets return to the calculation and calculate the right on one of the curves. Lets assume that the Installation pit some sand and silt in the beginning, and well
required head the pump must produce. Lets head requirement had only been 100 m. In that development is the process of pumping a new well
assume case there is no curve matching the duty point, free from sand and silt. It is done by pumping with
which is between two curves. a very high flow, which draws the fine particles in
the application device use 0.5 bar of pressure or the aquifer into the filter of the well. This slowly
5 m head The solution is to select one of the two curves: Sealing
makes the filter more effective. After approximately
the friction loss in the pipes, elbows, valves and if the upper curve is selected there is a bit more one day of pumping, the well is normally pumped
tees has been calculated to 2.5 bar, or 25 m head reserve in the pump, if the lower one is selected clean, and is ready for normal operation.
Borehole
lets assume the elevation lift is only 20 m head the pump will run marginally for a longer time.
Static water level is 50 m (this corresponds to In both cases it has no practical influence on the The pump used for well development wears out
suction lift for a surface pump) performance or the efficiency, which can be seen relatively quickly because of the high sand content,
the drawdown in the well is 3 m from the efficiency curve. Well casing and it should therefore always be replaced with a
Total head requirement to the pump is therefore new pump as soon as the well does not produce
5+25+20+50+3=103 m. Groundwater wells any more sand.
A well is an opening stretching from the ground
We earlier calculated the flow and found a surface to the underground aquifer, where the The submersible pump must always be installed
Grundfos submersible pump SP215 meets this groundwater is located. The depth of the well may Aquifer above the screen area of the casing. This is to ensure
requirement. Looking at the pump performance vary from a few meters to several hundred meters. that the water is forced past the motor, providing
curves we can see that a 4 stage pump can meet adequate motor cooling. If the pump cannot be
the head requirement of 103 m. Wells are typically drilled with special drilling installed above the screen filter, a cooling sleeve is
equipment able to penetrate the various layers of recommended to create the necessary flow along
Gravel pack/
The pump curve below shows that a 4 stage pump the ground, such as sand, clay, bedrock, and the like. Sand filter the motor for proper cooling.
will give exactly thedata
flow and head required. The SPInside the drilled hole a casing (pipe) is typically
4 Performance curves and technical A, SP
pump is a submersible pump, type SP215-4 (4 installed, which prevents the well from collapsing The drawdown for each specific well can be tested
stages or bowls) with a 75 kW motor. around the pump. Screen filter using a test pump with the same flow rating as
the production pump, which is installed in the
SP 215
SP 215
In this example the performance requirement was
Performance curves
Below the casing and in line with the aquifer is well and the pump started. The groundwater
another casing with fine slots. This is the well level is recorded, and the equilibrium point has
p H
[kPa] [m]
SP 215 screen, where the slots allow the water to enter the been reached when the water level has become
2400
240
-6
50 Hz
ISO 9906:2012 Grade 3B
well. It holds back sand and larger particles trying To improve the filtering function, the borehole constant. This level is the dynamic water level. The
220
-6-A
to enter the well. typically features a diameter that is 2-3 larger drawdown is the difference between the static and
than the casing. A fine sand gravel pack filter is the dynamic water level.
-6-AA
2000
-5-A
180
-5-AA
casings come with a pre-made gravel pack filter. All the water the well is producing is pushed
1600
160 -4
Made correctly, this filtering method prevents sand through the aquifer and the well screen by the
-4-A and silt from entering the well. pressure differential there is between the static
140
-4-AA and the dynamic water level. The higher the flow is,
1200
120 -3 The US EPA and National Water Works Association the bigger the drawdown will be. For this reason it
-3-A are recommending the following sand limits in is often better, considering operating costs, to use
100 -3-AA
well water: two or more smaller pumps (and wells) instead of
800 80 -2
one large one. With smaller pumps the drawdown
60
-2-A
1 ppm in water for drip and microspray is limited, and the elevation lift is reduced.
-2-AA
application.
10 ppm in water for sprinkler irrigation systems. Some aquifers have so much resistance that the
400 40 -1
-1-A
20 15 ppm in water for flood irrigation. water flow to one well is not enough to cope with
the irrigation need. A second and third well may
0 0
0 40 80 120 160 200 240 280 Q [m/h] Before the well can be put into operation, it must be the only solution to get the amount of water
0 20 40 60 80 Q [l/s] be developed. A new well will always produce required.
p H Eta
[kPa] [m] [%]
160 16 Eta 80
120 12 60
80 8 40
TM00 8785 4702
94 040 4
0
NPSH 20
0
95
0 40 80 120 160 200 240 280 Q [m/h]
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Pump performance installing another pump should be considered. Wear from sand and other abrasive materials in device. Grundfos submersible motors have a
Maintaining pump performance is fairly simple the water built-in temperature transmitter that sends a
and requires monitoring of just three parameters: 2) The water or pressure requirements have Sand will over time destroy the pump signal to an above-ground protection device
changed completely, and already from very early in the with no extra wires, thus making the installation
1. flow If another section of irrigated land has been process a loss of efficiency can be seen. A deep very simple.
2. pressure added, or taken out, or the flow requirements well designed correctly will not produce sand
3. power consumption have changed significantly, a change of pump of significant quantities. But in many cases the General overload
must be considered; also if the irrigation system well has not been made properly, and it will A general overload of the pump and motor will
From the three parameters the pump efficiency can has been changed to a less water consuming continue to produce sand for as long as it is in cause the temperature in the motor to increase
be calculated: application. use. In such cases, the only way to avoid sand and eventually destroy the motor. It is therefore
entering the pump is effective filtering before important always to install a good overload
HxQ
Pump efficiency = 367 x P1
3) The pump is losing efficiency and needs repair or the pump inlet. device, such as the MP204 described in Chapter
replacement 8 above. This device will protect against all the
where Pumps losing efficiency typically occur for the possible disturbances that may occur, including
H is the pump head in meters (m) following reasons: Bad Power Supply overload.
Q is the flow in cubic meters per hour (m3/h) A bad power supply may destroy the electric
P1 is the motor power consumption in Water hammer motor.
kilowatts (kW) Water hammer is a problem that can occur over voltage or in particular under voltage
when water is flowing in a pipe and a valve above + / - 10%
Please note that the formula above calculates is closed too quickly. The longer the pipe, the phase unbalance with more than 3%
both motor and pump-end efficiency as one total worse the impact; and water hammer happens deviation between phase voltage
number. A comparison with the pump literature because water cannot be compressed. This can voltage spikes from other equipment
can therefore not be made, as this data is pumps- be compared with a long train in motion, which starting and stopping, and in particular from
only efficiencies. also needs some time to come to a complete lightning.
stop. If it is forced to stop in a split second it
When checking the pressure, remember to add the destroys itself and everything that is trying to Grundfos offers a special overload device that
elevation lift and friction loss from the discharge stop it. takes care of all of the above.
to the gauge, if the pressure gauge is not installed
directly at the pump discharge. This must always When water hammer happens it can be High temperatures
be done for a deep well pump. identified as a loud noise, as when someone High temperatures can occur because of too
is hammering on the pipes. Water hammer high ambient temperatures, or because the
If these parameters are recorded right after the can destroy both the pump, pipes, valves and cooling is not good enough. Electric motors
pump has been installed, they can be checked other components in the system. normally have their maximum ambient
at regular intervals, or even better, with on-line temperature shown on the nameplate. Make
monitoring equipment that can be set to give A way to avoid water hammer is by introducing sure that is not exceeded and that the motor
alarms if some of the parameters are changing, or an air buffer somewhere in the pipeline. This can get rid of the heat generated.
exceeding a pre-set limit. could be a pressure tank containing air, and
since air is compressible the energy in the Submersible pump motors are cooled by the
If deviations from the pre-set conditions occur flowing water can be absorbed by the air water that is being pumped, and if that water
there are typically three main reasons why: volume. Another way to avoid water hammer is is not removed quickly enough it will slowly
to introduce a soft start and stop of the pump. If heat up and exceed the maximum allowable
1) The pumps operating conditions have changed the pump is equipped with a variable frequency temperature for that motor.
For example, if the water table in a well drops and drive (VFD), it will also have a soft start and
the pump has to deliver a bigger head; the duty probably also a soft stop. Since VFDs are good Some motors come with built in temperature
point is actually moving to the left on the pump for general pump performance regulation, it sensors which will stop the motor whenever a
curve. Perhaps a valve in the system is throttling is the recommended approach to avoid water pre-set temperature has been exceeded. Others
more or less than previously. If the conditions hammer. require a separate signal wire is to transmit the
could be changed back, they should. If not, temperature signal to a temperature overload
96 97
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
9. General guidelines
98 99
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
9. General guidelines
Flow sleeve on
SP pumps horizontally installed
pump.
When installing and using SP pumps there are
some things to remember, and these are listed
below with drawings.
Submersible Submersible
motor fitted with pump set with
Vortex baffle plate on
anode strimgs sacrificial zinc
horizontally-installed
anodes
pump (seen from
above)
100 101
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
With horizontal installation, using a flow sleeve Corrosion influenced by Impact on corrosion resistance:
is recommended in the following situations:
Product form of material of construction (sheet/ Corrosion resistance of cast stainless steel is
plate or cast components) usually lower that the corresponding milled
stainless steel quality (plate/sheet/strip).
An example is EN 1.4401 and EN 1.4408.
Thickness of material Perforation by corrosion will take longer and
thereby increase the lifetime.
Frequency drive to ensure min.
flow of 0.15 m/s around to motor Surfaces with heat transfer (such as SP and The higher surface temperature will decrease
To avoid scaling deposit around S-pumps) the corrosion resistance.
the motor if iron or manganese is present Fabrications methods, such as welding If not properly welded the corrosion resistance
Avoid solids and silt to built up around the can be reduced
motor which will damage the shaft seal Design of pump The resistance to corrosion is markedly affected
If feeding above motor by the design.
If gas/air bubbles are present the pump must Corrosion and material
be equipped with either a gas sleeve or the The Likelihood of corrosion depends on:
water level must be minimum 30 m above the The grade of material used
pump inlet (GG-AISI 304 - AISI 316 - AISI 904L)
Chloride concentration in the water
Electrochemical potential of the metal
exposed to media
Temperature
Oxygen concentration
Velocity of the media in contact with the
metalic surface
The pH value
102 103
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Pump type Drinking water 500 -1000 1000-2000 2000-5000 5000- 10000 Seawater Corrosion Impact on corrosion
Chloride [mg/l] Chloride [mg/l] Chloride [mg/l] Chloride [mg/l] influenced by resistance:
pH value > 6.5 pH value > 6.5 pH value > 6.5 pH value > 6.5 Product form of Corrosion resistance
CR (cast iron, EN 1.4301) () material of construc- of cast stainless steel
tion (sheet/plate or is usually lower that
CRI (EN 1.4301) ()
cast components) the corresponding
CRN (EN 1.4401) (max. 30C) () () () ()
milled stainless steel
CRT (titanium) (max. 80C) (max. 80C) (max. 80C) (max. 80C) (max. 80C) quality (plate/sheet/
NB/NK cast iron () strip).
NB/NK (cast iron, EN 1.4401 impeller) () () An example is EN
1.4401 and EN 1.4408.
NB/NK N (EN 1.4408) (max. 50C) (max. 35C) (max. 10C) () ()
Thickness of material Perforation by corro-
NB/NK R (EN 1.4517) (max. 45C) (max. 35C) (max. 30C) (max. 25C)
sion will take longer
SL (cast iron) () and thereby increase
SL (cast iron, EN 1.4401 impeller) () () the lifetime.
SE (cast iron) () Surfaces with heat The higher surface
SE (cast iron, EN 1.4401 impeller) () () transfer (such as SP- temperature will
and S-pumps) decrease the corro-
SE R (EN 1.4408) (max. 40C) (max. 25C) () () ()
sion resistance.
SE D (EN 1.4517) (max. 35C) (max. 30C) (max. 25C) (max. 20C)
Fabrications meth- If not properly
SP standard (EN 1.4301) ()
ods, such as welding welded the corrosion
SPN (EN 1.4401) (max. 50C) (max. 35C) () () () resistance can be
SPR (EN 1.4539) (max. 45C) (max. 36C) (max. 30C) (max. 25C) reduced
Design of pump The resistance to
: Suitable (): Limited (reduced lifetime must be expected) : Poor corrosion is marked
affected by the
Comments: design.
1. At chloride contents above 1000 mg/l longer periods of standstill must be avoided in order to reduce
the risk of corrosion
2. As regards cast iron an increase in the corrosion rate must be expected in liquids with pH value lower
then 6.5.
3. At pH values above 10 the corrosion resistance of cast iron and stainless steel towards chloride will
increase
4. A high sulphate (SO4--) content will decrease the corrosivety of chloride to stainless steel, but increase
the corrosivety to cast iron. This is very often the case within mining and in such cases the resistance
curves on the next pages should be used
104 105
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Corrosion resistance of pumps to chloride containing liquids (FOR GUIDANCE ONLY): Chloride 1) Find the chart that includes the relevant pump
Corrosion resistance charts for SP and NB/NK version and temperature.
pumps in mine water (acid leaching, dewatering,
Pump type Acids reducing Acids Alkalis and mine wastewater) 2) In this chart mark the point that represents the
oxidising chloride and sulphate concentrations in the
HCl H2SO4 H3PO4 HNO3 NaOH In some acid mine waters (especially sulphuric water for which the pump is to be used.
acid leach solutions) there is a high sulphate
CR () content compared to many other types of 3) Choose the curve that represents the actual
CRI chloride containing waters like brackish and pH-value of the water.
seawater.
CRN () If the marked point is located at or to the left of
CRT () () High sulphate content will exert a corrosion the curve the pump will be suitable for the water.
inhibiting effect as regards crevice corrosion If the marked point is located to the right of the
NB/NK cast iron () and pitting on stainless steel, which means that curve the pump will have limited resistance to the
NB/NK cast iron + SS () the pump can be used for a higher chloride/ water and a reduced lifetime must be expected.
temperature combination in case the sulphate Below the start point of a curve the sulphate
impeller
content is high as well. The following chart takes content is without any effect and the pump
NB/NK N () this effect into account. can be used without any considerations about
NB/NK R () the sulphate content (at this specific pH-value).
The diagrams should be used as follows: Above the end point of a curve the pump is not
SL () suitable for the specific pH-value represented by
SL SS impeller () this curve.
SE cast iron ()
SE cast iron SS impeller ()
N-version (SP, CR, NB/NK) + R-version (S) < 20C
Sulphate mg/l
40000
SE R ()
Poly. (N-version pH 1-3)
SE D ()
35000 Poly. (N-version pH 3-5)
SP standard () ()
Poly. (N-version pH>5)
SPN () () () 30000
SPR () () ()
25000
: Suitable (): Suitability depends on conc. and temp. : Poor
20000
15000
10000
5000
0
0 5000 10000 15000 20000 25000
Chloride mg/l
106 107
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
N-version (SP, CR, NB/NK) + D-version (S) 20-30C R-version (SP, NB/NK) + D-version (S) < 20C
Sulphate mg/l Sulphate mg/l
40000 70000
Poly. (N-version pH 1-3) R-version pH 3-5
25000
40000
20000
30000
15000
20000
10000
10000
5000
0 0
0 5000 10000 15000 20000 25000 0 5000 10000 15000 20000 25000 30000 35000
Chloride mg/l
Chloride mg/l
N-version (SP, CR, NB/NK) + R-version (S) 30-40C R-version (SP, NB/NK) + D-version (S) 20-30C
Sulphate mg/l Sulphate mg/l
70000
40000
Poly. (N-version pH 1-3) Poly. (R-version pH 1-3)
30000 50000
25000
40000
20000
30000
15000
20000
10000
10000
5000
0
0 0 5000 10000 15000 20000 25000 30000 35000 40000 45000
0 5000 10000 15000 20000 25000 Chloride mg/l
Chloride mg/l
108 109
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
R-version (SP, NB/NK) + D-version (S) 30-40C Vapour pressure p and density of water at different temperatures
Sulphate
t[C] T[K] P[bar] [kg/m3] t[C] T[K] P[bar] [kg/m3] t[C] T[K] P[bar] [kg/m3]
90000
Poly. (R-version pH 1-3) 0 273.15 0.00611 0999.8 138 411.15 3.414 927.6
1 274.15 0.00657 0999.9 61 334.15 0.2086 982.6 140 413.15 3.614 925.8
80000 Poly. (R-version pH 3-5) 2 275.15 0.00706 0999.9 62 335.15 0.2184 982.1 145 418.15 4.155 921.4
3 276.15 0.00758 0999.9 63 336.15 0.2286 981.6 150 423.15 4.760 916.8
Poly. (R-version ph>5) 4 277.15 0.00813 1000.0 64 337.15 0.2391 981.1
70000 5 278.15 0.00872 1000.0 65 338.15 0.2501 980.5 155 428.15 5.433 912.1
6 279.15 0.00935 1000.0 66 339.15 0.2615 979.9 160 433.15 6.181 907.3
7 280.15 0.01001 999.9 67 340.15 0.2733 979.3 165 438.15 7.008 902.4
60000 8 281.15 0.01072 999.9 68 341.15 0.2856 978.8 170 443.15 7.920 897.3
9 282.15 0.01147 999.8 69 342.15 0.2984 978.2 175 448.15 8.924 892.1
10 283.15 0.01227 999.7 70 343.15 0.3116 977.7
50000 180 453.15 10.027 886.9
11 284.15 0.01312 999.7 71 344.15 0.3253 977.0 185 458.15 11.233 881.5
12 285.15 0.01401 999.6 72 345.15 0.3396 976.5 190 463.15 12.551 876.0
40000 13 286.15 0.01497 999.4 73 346.15 0.3543 976.0 195 468.15 13.987 870.4
14 287.15 0.01597 999.3 74 347.15 0.3696 975.3 200 473.15 15.50 864.7
15 288.15 0.01704 999.2 75 348.15 0.3855 974.8
30000 16 289.15 0.01817 999.0 76 349.15 0.4019 974.1 205 478.15 17.243 858.8
17 290.15 0.01936 998.8 77 350.15 0.4189 973.5 210 483.15 19.077 852.8
18 291.15 0.02062 998.7 78 351.15 0.4365 972.9 215 488.15 21.060 846.7
20000 19 292.15 0.02196 998.5 79 352.15 0.4547 972.3 220 493.15 23.198 840.3
20 293.15 0.02337 998.3 80 353.15 0.4736 971.6 225 498.15 25.501 833.9
10000
21 294.15 0.02485 998.1 81 354.15 0.4931 971.0 230 503.15 27.976 827.3
22 295.15 0.02642 997.8 82 355.15 0.5133 970.4 235 508.15 30.632 820.5
0
23 296.15 0.02808 997.6 83 356.15 0.5342 969.7 240 513.15 33.478 813.6
0 5000 10000 15000 20000 25000 30000 35000
24 297.15 0.02982 997.4 84 357.15 0.5557 969.1 245 518.15 36.523 806.5
25 298.15 0.03166 997.1 85 358.15 0.5780 968.4 250 523.15 39.776 799.2
Chloride mg/l
26 299.15 0.03360 996.8 86 359.15 0.6011 967.8 255 528.15 43.246 791.6
27 300.15 0.03564 996.6 87 360.15 0.6249 967.1
28 301.15 0.03778 996.3 88 361.15 0.6495 966.5 260 533.15 46.943 783.9
29 302.15 0.04004 996.0 89 362.15 0.6749 965.8 265 538.15 50.877 775.9
30 303.15 0.04241 995.7 90 363.15 0.7011 965.2 270 543.15 55.058 767.8
275 548.15 59.496 759.3
31 304.15 0.04491 995.4 91 364.15 0.7281 964.4 280 553.15 64.202 750.5
32 305.15 0.04753 995.1 92 365.15 0.7561 963.8
33 306.15 0.05029 994.7 93 366.15 0.7849 963.0 285 558.15 69.186 741.5
34 307.15 0.05318 994.4 94 367.15 0.8146 962.4 290 563.15 74.461 732.1
35 308.15 0.05622 994.0 95 368.15 0.8453 961.6 295 568.15 80.037 722.3
36 309.15 0.05940 993.7 96 369.15 0.8769 961.0 300 573.15 85.927 712.2
37 310.15 0.06274 993.3 97 370.15 0.9094 960.2 305 578.15 92.144 701.7
38 311.15 0.06624 993.0 98 371.15 0.9430 959.6 310 583.15 98.700 690.6
39 312.15 0.06991 992.7 99 372.15 0.9776 958.6
40 313.15 0.07375 992.3 100 373.15 1.0133 958.1 315 588.15 105.61 679.1
320 593.15 112.89 666.9
41 314.15 0.07777 991.9 102 375.15 1.0878 956.7 325 598.15 120.56 654.1
42 315.15 0.08198 991.5 104 377.15 1.1668 955.2 330 603.15 128.63 640.4
43 316.15 0.08639 991.1 106 379.15 1.2504 953.7 340 613.15 146.05 610.2
44 317.15 0.09100 990.7 108 381.15 1.3390 952.2
45 318.15 0.09582 990.2 110 383.15 1.4327 950.7 350 623.15 165.35 574.3
46 319.15 0.10086 989.8 360 633.15 186.75 527.5
47 320.15 0.10612 989.4 112 385.15 1.5316 949.1
48 321.15 0.11162 988.9 114 387.15 1.6362 947.6 370 643.15 210.54 451.8
49 322.15 0.11736 988.4 116 389.15 1.7465 946.0 374.15 647.30 221.2 315.4
50 323.15 0.12335 988.0 118 391.15 1.8628 944.5
120 393.15 1.9854 942.9
51 324.15 0.12961 987.6
Vapour table 52 325.15 0.13613 987.1 122 395.15 2.1145 941.2
This table shows the vapour 53 326.15 0.14293 986.6 124 397.15 2.2504 939.6
54 327.15 0.15002 986.2 126 399.15 2.3933 937.9
pressure p [bar] and the density 55 328.15 0.15741 985.7 128 401.15 2.5435 936.2
[kg/m3] of water at different 56 329.15 0.16511 985.2 130 403.15 2.7013 934.6
57 330.15 0.17313 984.6
temperatures t [oC]. Likewise, 58 331.15 0.18147 984.2 132 405.15 2.8670 932.8
the table shows the correspond- 59 332.15 0.19016 983.7 134 407.15 3.041 931.1
60 333.15 0.19920 983.2 136 409.15 3.223 929.4
ing absolute temperature T [K].
110 111
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Orifice
Unit conversion tables Orifice
The conversion tables for pressure and flow show The duty point of a pump is adjusted by adding a
the most commonly used units in connection resistance in connected series with the pump. In practice,
with pumping systems this is normally done by placing an orifice in the outlet d Q DN
63 25 10 4
Pa, (N/m2) bar kp/m2 mWC at (kp/cm2) atm psl (lb/ln2) H= H= H= H=
1 00 =40 =16 =6.3 =2.5
H= H H H H
1 Pa 1 10-5 0.1020 1.020 x 10-4 1.020 x 10-5 9.869 x 10-4 1.450 x 10-4 1 Pa
100
1 bar 10 5
1 10197 10.20 1.020 0.9869 14.50 1 bar
Q [m3/h]
1 kp/m2 9.8067 9.807 x 105 1 10-3 10-4 0.9678 x 10-4 1.422 x 10-3 1 kp/m2
1 mWC 9806.7 0.09807 10 3
1 0.1 0.09678 1.422 1 mWC 10
Flow (volume)
Orifice [mm]
1 l/s 10-3 3.6 1 13.2 15.85 1 l/s Dn=40
Dn=32
1 UK GPM 7.577 x 10-5 0.02728 0.07577 1 1.201 1 UK GPM
1 US GPM 6.309 x 10-5 0.02271 0.06309 0.8327 1 1 US GPM Example:
The head of a pump, with an outlet flange of 125 mm,
10
has to be reduced by 25 m at a flow of 150 m3/h.
112 113
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
114 115
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
Environmental Management Systems gold mining sector through its life cycle, from O S
Processes and procedures that guide Newmont in manufacturing to transport to use and disposal. Open Pit Social Impact Assessment (SIA)
managing impacts to air, water and ecosystems, A mine where the minerals are mined entirely from A study undertaken to understand the potential
and the efforts we take to ensure our mines are International Organization for Standardization the surface. or actual social and economic impacts and
successfully reclaimed and land is restored for (ISO) opportunities (of exploration, mining, closure and
beneficial reuse. A global network that identifies what international Ore body rehabilitation) on communities.
standards are required by business, government A sufficiently large amount of mineral and rock
Erosion and society; develops them in partnership with the that can be mined economically. Sodium Cyanide
The breaking down and subsequent removal of sectors that will put them to use; adopts them by A chemical used in the processing of ore to dissolve
either rock or surface material by wind, rain, wave transparent procedures based on national input; Oxidation gold and silver.
action, freezing and thawing, and other processes. and delivers them to be implemented worldwide. A chemical reaction caused by exposure to oxygen
that result in a change in the chemical composition Sustainable Development
Exploration ISO 14001 of a mineral. Industrial development that does not detract from
Prospecting, sampling, mapping, diamond drilling An internationally accepted specification for the potential of the natural environment and
and other work involved in searching for ore. Newmont's environmental management system. P provides benefits to future generations.
It specifies requirements for establishing an Pregnant Carbon
F environmental policy; determining environmental Carbon that has fully adsorbed all the gold it can T
Feasibility study aspects and impacts of products/activities/ hold. Tailing
A comprehensive study undertaken to determine services; planning environmental objectives and Residual sand/rock that remains after ore is
the economic feasibility of a project; the conclusion measurable targets; implementing and operating R crushed and commodity has been extracted.
will determine if a production decision can be programs to meet objectives and targets; checking Reclamation
made and is used for financing arrangements. and corrective action; and management review. The process by which lands disturbed as a result of Tailing Storage Facility
Footprint The land area that is disturbed through mining activity are restored to support beneficial An engineered, constructed facility for the long-
the construction and operation of a mine. L land use. term storage of tailing. Usually referred to as
Leaching tailings dams
G A chemical process used to extract the commodity. Refining
Greenhouse Gas Protocol (GHG) The final stage of metal production in which W
Provides accounting and reporting standards M impurities are removed from the molten metal. Waste Rock
and guidance for companies and other types Mercury Rock within, around or above the orebody with
of organizations preparing a greenhouse gas A naturally occurring element that can be present Reforestation insufficient concentrations of metal for economic
inventory. in ore bodies, often in the mineral form of mercury Planting new trees to absorb carbon dioxide from recovery.
sulphide (HgS), called cinnabar. the atmosphere, provide habitats for animals and
H protect against soil erosion.
Heap Leaching Mill
A process whereby gold / silver / copper is extracted A processing facility where ore is finely ground Risk Assessments
by "heaping" crushed ore on sloping impermeable and thereafter undergoes physical or chemical The overall process of risk analysis and risk
pads and continually applying a weak cyanide treatment to extract valuable metals. evaluation using a systematic process to determine
/ sulpheric acid solution that dissolves the how often a specific event occurs or has the
commodity. The commodity-laden solution is then Milling potential to occur, the magnitude of the event's
collected for recovery. Sorts the ore by size, crushes the rock and extracts consequence, as well as prioritizing those events.
the gold. Roaster Heats ore to extract gold-bearing
High Grade sulphide concentrate.
Rich ore; the best ore in a deposit. N
NGOs Rock Armour
I Nongovernmental organizations Large rocks and vegetation that prevent erosion.
International Cyanide Management Code (ICMC)
A voluntary certification program that focuses
on the responsible cyanide management in the
116 117
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
118 119
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
120 121
GRUNDFOS MINING MANUAL GRUNDFOS MINING MANUAL
122 123
124
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